Case Study

Resolving Baghouse Burn Hole Issues in a Steel Plant
Challenge

Challenge
A steel plant in Oklahoma faced a recurring issue with burn holes in their fiberglass membrane filter bags in a baghouse system connected to one of their burners. Despite using high-temperature bags, embers from materials burned in the system caused holes, leading to frequent bag replacements and inefficiencies.
Key Problems Identified
► Ember Intrusion: Embers from burning materials (e.g., trash, pallets) were reaching the baghouse and damaging the bags.

► Unmonitored Components: The plant had an existing expanded metal “spark arrestor” system in the ductwork, but its condition had not been inspected or maintained for a long time.

► Uncontrolled Inputs: Operators could not regulate the materials fed into the burner, increasing the risk of embers and foreign debris entering the system.

Solution
A systematic inspection traced the issue back to a spark arrestor box installed in the ductwork before the baghouse. The spark arrestor plates, designed to capture embers before they reached the bags, were heavily damaged and full of large holes due to years of wear and lack of maintenance.
Steps Taken

► Inspection and Diagnosis: A thorough walkthrough of the system, from the pickup point to the baghouse, identified the deteriorated spark arrestor plates as the root cause.

► Replacement of Expanded Metal Plates: The worn-out plates were replaced with new ones to restore their effectiveness in stopping embers.

► Maintenance Plan: The plant implemented a regular inspection and replacement schedule for the spark arrestor plates to prevent future issues.

Outcome

► Eliminated Bag Damage: After replacing the spark arrestor plates, the burn holes in the bags stopped completely.

► Reduced Downtime & Costs: The plant avoided frequent bag replacements, saving both time and operational costs.

► Improved Awareness: The plant operators gained a better understanding of the critical role of spark arrestor maintenance in protecting the baghouse system.

Key Takeaway

Regular inspection and maintenance of critical components, such as spark arrestors, can prevent costly damage to baghouse systems. A proactive maintenance plan ensures system reliability and longevity, especially in applications where embers or other damaging elements are present.
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